Segmented composite panel with false joints and method for making the same

ABSTRACT

A method of forming a building panel is provided, with the building panel including facer and liner sheets surrounding a foam core. The method includes the steps of pre-notching the facer sheet at each false joint, roll forming the side joints of the facer sheet, bending the facer sheet, via a press operation, at the pre-notched area to form the false joint, such that the facer sheet is a continuous sheet across the false joint, and bonding the facer sheet having the false joint and the liner sheet to the foam core to form the building panel.

FIELD OF THE INVENTION

The present invention is directed toward composite architectural panelsand, more particularly, towards composite architectural panels withfalse joints and methods of making the same.

BACKGROUND OF THE INVENTION

Composite architectural wall panels have typically been manufactured inmulti-step processes which often involve both sheet manufacturers andpanel fabricators. Initially, a composite sheet is manufactured bylaminating metal skins to a plastic or foam core. An example of such acomposite sheet is the “ALUCOBOND” material produced by Alusuisse Group,Ltd., Zurich, Switzerland. Then, the sheets are typically shipped to afabricator where they are cut to size and routed so as to return theedges around the perimeter. Extrusions are typically fabricated andapplied to the panel perimeter to create panel joinery. Also, stiffenersare typically applied in the field to the major flattened portion of thepanel to reduce bowing of the panel under a load. All of the above tendsto represent a rather cumbersome and costly process.

Insulated composite architectural wall panels are typically manufacturedon a continuous manufacturing line with a continuous metal liner. Aseries of separate metal facer elements are placed in a foam line andthe panels are formed by bonding the facer sheets and the metal liner toa core material (e.g., foam). The panels are cut or separated at theends of the facer sheets. The standard finished panel product has asingle liner element and a single facer element (the liner and facerelements, or sheets, are typically referred to in the industry as “metalskins”). When needed, a series of facer sheets are combined over oneliner sheet to make a larger and longer panel. The intermediate jointsbecome false joints, as shown in FIG. 1. The separate facer elements arejoined within a panel at the false joints, which give a larger panel theappearance of separate smaller panels.

In the erection phase, the panels are typically attached to a steelframe. The insulation costs of the panels is a function of their size inlength and width. When short panels are required, the per unitinstallation costs of the panels is quite high. To mitigate this highcost, panels having false joints as described above have been used whichinclude several facer element segments over one liner element in thecompleted panel to give the appearance of shorter panels. The severalfacer element segments were connected together to form the false joints,which gives the panel the appearance of several shorter panels. FIG. 1is a partial cross-sectional view of such a prior art panel, showngenerally at 10, at the false joint 12.

As shown in FIG. 1, the panel 10 includes a continuous liner element 14and separate facer elements 16 and 18 bonded to an insulating structuralcore 20. The separate facer elements 16 and 18 are bent inward at thefalse joint 12 and coupled together by a false joint receiver clip 22. Afalse joint gasket 24 is connected to the receiver clip 22 to providethe appearance of a panel joint at the false joint 12. As shown in FIG.1, a sealant 26 may be provided on inside surfaces of the facer elements16 and 18 at the false joint 12 at the connection with the receiver clip22.

Forming larger panels having the separate facer elements forming thefalse joints became quite cumbersome and costly in the plant. Qualityissues also arose due to panel length variations and the use of separatefacer elements to form the false joints. The successfully completedunits did, however, illustrate that there are advantages in field laborsavings to be realized in using larger panels having false joints.

The present invention is directed toward overcoming one or more of theabove-identified problems.

SUMMARY OF THE INVENTION

The present invention simplifies the formation of false joints in largercomposite architectural panels using a continuous facer element alongwith a continuous liner element bonded to a core material. The falsejoints can be formed at any position along the length of the panel, andallows various aesthetic designs to be achieved through strategicattachment of the panels to the building frame. One such design that canbe achieved is a masonry brick design where the false joints are placedsuch that the panels have a staggered appearance. Also by staggering thepanels a running bond appearance is achieved. The panels may be flat orhave a textured surface, and by embossing or chamfering the flat area ofthe panel, a stone effect can be achieved. Also, this process allows agreater number of false joints and a shorter length of facer sheetbetween the false joints as compared to the prior art of individualfacer sheets between the false joints.

In one form of the invention, a method of forming a building panel isprovided, with the building panel including facer and liner sheetssurrounding a core material. The method includes the steps ofpre-notching the facer sheet at each false joint, roll forming the sidejoints of the facer sheet, bending the facer sheet, via a pressoperation, at the pre-notched areas to form the false joints, such thatthe facer sheet is a continuous sheet across the false joints, andbonding the facer sheet having the false joints and the liner sheet tothe core material to form the building panel.

The facer sheet is also pre-notched at each real joint, and the buildingpanels are cut to length at each real joint. The core material istypically an insulating material such as foam, however, other corematerials are also contemplated.

In one form, a rubber gasket is placed into the false joint, and isadhered to the facer sheet at the false joint by an adhesive. The rubbergasket provides the appearance of a real joint at the false joint which,in turn, provides the appearance of smaller panels. Of course, the falsejoint may simply be left as is without attaching the rubber gasket.

The false joint includes a depression formed in the facer sheet, withthe depression including a base surface extending into the foam core andopposing side surfaces connecting the base surface to the exterior faceof the facer sheet. Tabs are provided, one each on the opposing sidesurfaces, at the pre-notched area, and the tabs are folded under one ofthe side joints of the facer sheet in the formation of the false joint.In one form, the one side joint of the facer sheet includes a slopedshelf, wherein the tabs are folded under the sloped shelf in theformation of the false joint.

A further method of forming a building panel is provided, the buildingpanel including facer and liner sheets surrounding a core material. Themethod generally includes the steps of pre-notching the facer sheet,which is provided in the form of a coil of sheet material having alength and opposed ends defining a width, at the opposed ends at eachfalse joint along the length of the facer sheet. The facer sheet is alsopre-notched at the opposed ends at each real joint along the length ofthe facer sheet. The opposed ends of the facer sheet are roll formed toform side joints, and the facer sheet is bent across its width, via apress operation, at the pre-notched areas to form the false joints, suchthat the facer sheet is a continuous sheet across the false joints. Thefacer sheet is cut at each real joint to form a plurality of facersheets, and the plurality of facer sheets having the false joints andthe liner sheet are bonded to the core material. The core material andliner sheet are then cut at each real joint of the facer sheets to formseparate building panels.

A building panel is also provided in accordance with the presentinvention including a facer sheet having opposed side joints defining awidth, a liner sheet, a core material bonded between the facer and linersheets, and at least one false joint formed in the facer sheet extendingbetween the side joints, such that the facer sheet is a continuous sheetacross the at least one false joint. The false joint includes a basesurface extending into the foam core, opposing side surfaces connectingthe base surface to the facer sheet, and a tab formed one each on theopposing side surfaces at one of the side joints, with the tabs foldedunder the one side joint in the formation of the false joints.

The false joint is generally U-shaped in cross-section, and a jointclosure is provided on the one side joint at the false joints.

It is an object of the present invention to reduce manufacturing and/orinstallation costs associated with composite panels having false joints.

It is a further object of the present invention to provide a compositepanel having false joints with improved thermal efficiency.

It is yet a further object of the present invention to provide acomposite panel having false joints with a continuous facer elementacross the false joints.

It is still a further object of the present invention to increase thestrength of composite panels having false joints.

Other objects, aspects and advantages of the present invention can beobtained from a study of the specification, the drawings, and theappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial cross-sectional view of a prior art composite panel;

FIG. 2 is a partial cross-sectional view of a composite building panelin accordance with the present invention;

FIG. 3 is a top view of a facer sheet being rolled off of a coil in themanufacture of a composite building panel in accordance with the presentinvention;

FIG. 4 is a side view of the facer sheet of FIG. 3 after roll forming ofthe side joints;

FIG. 5 is a cross-sectional view taken along line 5-5 in FIG. 3 afterformation of the false joint;

FIG. 6 is a perspective view of a composite building panel at the falsejoint in accordance with the present invention;

FIG. 7 is a top view of a facer sheet being rolled off of a coil in themanufacture of an alternate composite building panel in accordance withthe present invention;

FIG. 8 is a side view of the facer sheet of FIG. 7 after roll formingthe side joints;

FIG. 9 is a cross-sectional view taken along line 9-9 in FIG. 7 afterformation of the false joint;

FIG. 10 is a perspective view of the alternate composite building panelat the false joint in accordance with the present invention;

FIG. 11 is a cross-sectional view illustrating attachment of twoadjacent building panels; and

FIG. 12 is a partial view of a wall illustrating the inventive attachedto form a masonry brick design.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 2 illustrates a partial cross-sectional view of a compositebuilding panel, shown generally at 30, manufactured in accordance withthe present invention, at one of its false joints. The building panel 30includes a liner element 32, a facer element 34, and a core material 36bonded to the liner 32 and facer 34 elements and filling the interiorspace of the building panel 30. The liner 32 and facer 34 elements mayalso be referred to herein as sheets. Typically, the core material 36 isan insulating, structural foam core made from a foam or polymer (e.g.,polyurethane). However, other core materials may be used withoutdeparting from the spirit and scope of the present invention.

As shown in FIG. 2, the building panel 30 includes a false joint 38formed therein at predefined positions along the length of the facerelement 34. Typically, the liner element 32 defines the interior surfaceof the building panel 30, while the facer element 34 is the exteriorsurface of the building panel 30 which is viewable.

The false joint 38 is formed a press operation and includes a basesurface 40 which extends into the core material 36 and is generallyparallel to the facer element 34. The false joint 38 further includesopposing side surfaces 42 and 44 connecting the base surface 40 to thefacer sheet 34, with the opposing side surfaces 42 and 44 generallyperpendicular to the base surface 40 and facer element 34. In this form,the false joint 38 generally has a U-shaped cross-section (see FIG. 5).While the false joint 38 is described herein as having a U-shapedcross-section, the false joint 38 may have other shapes, such as aV-shaped cross-section, etc., depending upon a desired application andappearance.

A gasket 46 is provided in the false joint 38 and is attached to thebase surface 40 by means of an adhesive (not shown) or otherconventional means. In a preferred form, the gasket 46 is a rubbergasket, but may be made of other materials without departing from thespirit and scope of the present invention. The gasket 46 provides thefalse joint 38 with the appearance of a real joint between adjacentpanels, thus allowing a larger panel to be manufactured which has theappearance of several shorter panels. This helps to reduce installationcosts when the appearance of shorter panels is desired.

The liner 32 and facer 34 sheets are typically provided in coil form,and are rolled off of the coils to form the building panels. FIG. 3illustrates the facer sheet 34 being rolled off of such a coil in thedirection of arrow 50. The facer sheet 34 includes a length defined bythe rolled coil, and a width defined by opposed ends 52 and 54. Informing the building panels, the facer sheet 34 is pre-notched at theopposed ends 52, 54 along its length at each of the false joints 38. Asshown in FIG. 3, the end 54 includes a pre-notch 56 having a generallyrectilinear shape, while the end 52 includes a pre-notch 58 alsogenerally rectilinear in shape. The pre-notched areas 56 and 58 aresized to accommodate the base 40 and opposing side surfaces 42 and 44,which will be bent via a press operation to form the false joint 38.

The pre-notched area 58 includes tabs 60 and 62 which extend from theends of the opposed side surfaces 42 and 44, respectively. These tabs 60and 62 will be folded under a side joint formed at the end 52 in theformation of the false joint 38, as will be described hereafter.

The facer sheet 34 is also pre-notched along its length at each realjoint, which defines an end of a building panel. Thus, each buildingpanel may have any number of false joints formed in it between each ofthe real joints. The number of false joints will depend on the desiredappearance of the building panel.

After the facer sheet 34 is pre-notched at each of the false and realjoints, the side joints of the facer sheet 34 are roll formed at itsopposed end 52 and 54, as is known in the relevant art. FIG. 4illustrates a side view of the facer sheet 34 after roll forming theside joints 64 and 66. The side joint 64 and 66 are formed such that theside joint 66 of one building panel will engage the side joint 64 of anadjacent building panel. In one form, the side joint 64 is formed suchthat it includes a sloped shelf 68 and an edge-hook connection 70. Thesloped shelf 68 is designed such that water will run off of the buildingpanel instead of connecting thereon, and may include apertures formedtherein for drainage purposes. The edge-hook connection 70 is designedsuch that it engages a corresponding female receptacle 72 formed in sidejoint 66 of an adjacent building panel.

After the side joints 64 and 66 are roll formed, the false joints areformed across the facer sheet 34 via a press operation. As shown in FIG.3, the false joints are formed by bending the facer sheet 34 between thepre-notched areas along the bend lines 74. After bending, thefalse-joint 38 is typically U-shaped, as shown in FIG. 5, and includesthe base surface 40 extending into the core material 36 and the opposingside surfaces 42 and 44.

As shown more clearly in FIG. 6, when the false joint 38 is pressformed, the tabs 60 and 62 are folded under the side joint 64. Morespecifically, the tabs 60 and 62 are folded under the sloped shelf 68 ofthe side joint 64. This helps to provide structural rigidity to thefalse joint 38.

The facer element 34 is then cut to length at each of thepre-established real end joints to form a plurality of facer sheets.Each of the facer sheet panels is then placed onto a foam line, and thepanels are foamed by bonding the facer sheets and the liner sheet 32 toa core material 36. After such bonding, the finished building panels arecut to length at the pre-established real end joints to form separatebuilding panels. Since the facer element 34 has already been cut, thiscutting typically involves only cutting through the core material 36 andthe liner element 32.

While the facer sheets have been described as being precut to a panellength before foaming, the facer sheet 34 may be maintained as onecontinuous sheet and cut to the various panel sizes after foaming.

A gasket 46 is placed in the false joint 38 and adhered to the basesurface 40 by means of an adhesive (not shown). The gasket 46 providesthe appearance of a real joint at each false joint 38. Sincepre-notching the facer sheet 34 will result in discontinuities at theside joint 64, a joint closure element 76 (see FIG. 6) is provided atthe side joint 64 of the finished panels at each false joint to closethe false joint at the side joint 64.

The depth of the false joint 38 is generally dictated by the thicknessof the panel. As shown in FIG. 4, the false joint 38 has a depthcorresponding to the dotted line 78. This depth is generally limited bythe thickness of the facer sheet 34 at its end joint 66. For example,for a panel having a 2-inch thickness, the maximum thickness of thefalse joint will typically be approximately ¾-inch. However, other depthdimensions of the false joints are contemplated without departing fromthe spirit and scope of the present invention.

FIG. 7-10 illustrate forming a building panel 30′ having a greaterthickness than that described with respect to FIG. 2-6, with likeelements of FIGS. 2-6 indicated with the same reference number and thoseelements requiring modification indicated with a prime (′).

FIG. 7 illustrates the facer sheet 34′ coming off a coil in thedirection of arrow 80 in the formation of a building panel having agreater thickness. The facer sheet 34′ includes a length defined by therolled coil, and a width defined by opposed ends 52′ and 54′. In formingthe building panels, the facer sheet 34′ is pre-notched at the opposedends 52′, 54′ along its length at each of the false joints 38′. As shownin FIG. 7, the end 54′ includes a pre-notch 56′ having a generallyrectilinear shape, while the end 52′ includes a pre-notch 58′ alsogenerally rectilinear in shape. The pre-notched areas 56′ and 58′ aresized to accommodate the base 40′ and opposing side surfaces 42′ and44′, which will be bent via a press operation to form the false joint38′. As shown in FIG. 7, the pre-notched areas 56′, 58′ of the falsejoints are thicker to accommodate the greater depth of the false joint38′.

The pre-notched area 58′ includes tabs 60′ and 62′ which extend from theends of the opposed side surfaces 42′ and 44′, respectively. These tabs60′ and 62′ are folded under a side joint formed at the end 52′ in theformation of the false joint 38′. More specifically, as shown in FIG.10, the tabs 60′ and 62′ are folded under the sloped shelf 68′ formed atside joint 64′.

The facer sheet 34′ is also pre-notched along its length at each realjoint, which defines an end of a building panel. Thus, each buildingpanel may have any number of false joints formed in it between each ofthe real joints. The number of false joints will depend on the desiredappearance of the building panel. In forming the false and real joints,one set of hydraulic presses and dies may be utilized, or two sets ofhydraulic presses and dies may be implemented, with one set notching thefalse joints and the other set notching the real joints.

After the facer sheet 34′ is pre-notched at each of the false and realjoints, the side joints of the facer sheet 34′ are roll formed at itsopposed end 52′ and 54′, as is known in the relevant art. FIG. 8illustrates a side view of the facer sheet 34′ after roll forming theside joints 64′ and 66′. The side joints 64′ and 66′ are formed suchthat the side joint 66′ of one building panel will engage the side joint64′ of an adjacent building panel. As previously described, the sidejoint 64′ is formed such that it includes a sloped shelf 68′ for waterrun off and an edge-hook connection 70′ designed such that it engages acorresponding female receptacle 72′ formed in side joint 66′ of anadjacent building panel.

After the side joints 64′ and 66′ are roll formed, the false joints areformed across the facer sheet 34′ via a press operation. As shown inFIG. 7, the false joints are formed by bending the facer sheet 34′between the pre-notched areas along bend lines 74′. After bending, thefalse-joint 38′ is typically U-shaped, as shown in FIG. 9, and includesthe base surface 40′ extending into the core material 36 and theopposing side surfaces 42′ and 44′.

As shown more clearly in FIG. 10, when the false joint 38′ is pressformed, the tabs 60′ and 62′ are folded under the side joint 64′. Morespecifically, the tabs 60′ and 62′ are folded under the sloped shelf 68′of the side joint 64′. This helps to provide structural rigidity to thefalse joint 38′.

As previously described, the facer element 34′ is then cut to length ateach of the pre-established real end joints to form a plurality of facersheets. Each of the facer sheet panels is then placed onto a foam line,and the panels are foamed by bonding the facer sheets and the linersheet 32 to a core material 36. After such bonding, the finishedbuilding panels are cut to length at the pre-established real end jointsto form separate building panels. Since the facer element 34′ hasalready been cut, this cutting typically involves only cutting throughthe core material 36 and the liner element 32.

As previously noted, while the facer sheets have been described as beingprecut to a panel length before foaming, the facer sheet may bemaintained as one continuous sheet and cut to the various panel sizesafter foaming.

A gasket 46 is placed in the false joint 38′ and adhered to the basesurface 40′ by means of an adhesive (not shown). The gasket 46 providesthe appearance of a real joint at each false joint. Since pre-notchingthe facer sheet 34′ will result in discontinuities at the side joint64′, a joint closure element 76 (see FIG. 10) is provided at the sidejoint 64′ of the finished panels at each false joint to close the falsejoint at the side joint 64′.

As previously noted, the depth of the false joint 38′ is generallydictated by the thickness of the panel. As shown in FIG. 8, the falsejoint 38′ has a depth corresponding to the dotted line 78′. This depthis generally limited by the thickness of the facer sheet 34′ at its endjoint 66′. For example, the facer sheet 34′ is designed for a panelhaving a 3-inch thickness. For a 3-inch thick panel, the false joint 38′will typically have a depth of 1¾ inches. However, the present inventioncontemplates other false joint depths.

After the panels have been formed, FIG. 11 illustrates the horizontaljoint formed at the connection between adjacent building panels. Asshown therein, a bottom panel 90 is connected to a building frame via aconnector 92. The edge-hook connector 70, 70′ and male connector 94formed at side joint 64, 64′ are received in corresponding femaleconnectors 72 and 96 formed in the side joint 66, 66′ of an adjacentbuilding panel 98. A sealant 100 may be applied at the connectionbetween the male 94 and female 96 connectors.

Various aesthetic designs can be achieved through strategic attachmentof the panels to a building frame. One such design that can be achievedis a masonry brick design, as shown in FIG. 12 at 102. The panels 30,30′ are attached such that the false joints 38, 38′ and the real joints104 have a staggered appearance. As shown in FIG. 12, each panel 30, 30′includes two false joints 38, 38′, however, each panel may have anynumber of false joints without departing from the spirit and scope ofthe present invention. Through use of the inventive panels, installationcosts are reduced since smaller individual panels are not needed. Theinventive panels having the false joints provide the appearance ofsmaller panels without an installer having to attach each smaller panelseparately. The panels 30, 30′ may be flat or have a textured surface,and by embossing or chamfering the flat area of the panel, a stoneeffect can be achieved. Thus, the inventive panels offer many designvariations.

Building panels formed in accordance with the present invention have afacer element that is continuous and easier to handle. As a result,there is continuous metal through the false joints, since they arestamped into the facer element. In addition to the improvedmanufacturing process, the panels also realize other benefits regardingaesthetics, strength and thermal efficiency.

While the present invention has been described with particular referenceto the drawings, it should be understood that various modificationscould be made without departing from the spirit and scope of the presentinvention. For example, the present invention may be used to form panelshaving virtually any width and length. Also, the various rollers anddies utilized to form the various joinery may be modified to manufacturepanels having any size false joint, as will be readily understood by oneof ordinary skill in the art.

1. A method of forming a building panel including facer and liner sheetssurrounding a core material comprising the steps of: pre-notching thefacer sheet at each false joint; roll forming side joints of the facersheet; bending the facer sheet at the pre-notched area to form the falsejoint, wherein the facer sheet is a continuous sheet across the falsejoint; and bonding the facer sheet having the false joint and the linersheet to a core material to form the building panel.
 2. The method ofclaim 1, further comprising the steps of: pre-notching the facer sheetat each real joint; and cutting the building panel to length at eachreal joint.
 3. The method of claim 1, further comprising the step ofplacing a gasket into the false joint.
 4. The method of claim 3, whereinthe gasket is adhered to the facer sheet at the false joint by anadhesive.
 5. The method of claim 1, wherein the false joint comprises adepression formed in the facer sheet, the depression comprising a basesurface extending into the foam core and opposing side surfaces.
 6. Themethod of claim 5, wherein the false joint comprises tabs provided oneeach on the opposing side surfaces at the pre-notched area, wherein thetabs are folded under one of the side joints of the facer sheet in theformation of the false joint.
 7. The method of claim 6, where the oneside joint of the facer sheet include a sloped shelf, and wherein thetabs are folded under the sloped shelf in the formation of the falsejoints.
 8. The method of claim 1, wherein the facer sheet is provided asa coil of sheet material.
 9. The method of claim 1, where the facersheet is made of a metallic material.
 10. The method of claim 1, wherethe false joints are formed via a press operation.
 11. The method ofclaim 1, wherein the core material comprises an insulating foam corematerial.
 12. A method of forming a building panel including facer andliner sheets surrounding a core material comprising the steps of:providing a facer sheet in the form of a coil of sheet material, thefacer sheet having a length and opposed ends defining a width;pre-notching the facer sheet at the opposed ends at each false jointalong the length of the facer sheet; pre-notching the facer sheet at theopposed ends at each real joint along the length of the facer sheet;roll forming the opposed ends of the facer sheet to form side joints;bending the facer sheet across the width of the facer sheet at thepre-notched areas to form the false joints, wherein the facer sheet is acontinuous sheet across the false joints; cutting the facer sheet ateach real joint to form a plurality of facer sheets; providing a linersheet in the form of a coil of sheet material; bonding the plurality offacer sheets having false joints and the liner sheet to a core materialto form building panels; and cutting the core material and liner sheetat each real joint of the facer sheets to form separate building panels.13. The method of claim 12, further comprising the step of attaching agasket into the false joint.
 14. The method of claim 12, wherein thefalse joint comprises a depression formed in the facer sheet, thedepression comprising a base surface extending into the foam core andopposing side surfaces.
 15. The method of claim 14, wherein the falsejoint comprises a tab formed on each of the opposing side surfaces atone of the pre-notched areas at the false joint, wherein the tabs arefolded under the side joint of the facer sheet in the formation of thefalse joints.
 16. The method of claim 15, wherein the side joint of thefacer sheet includes a sloped surface, and wherein the tabs are foldedunder the sloped surface in the formation of the false joints.
 17. Themethod of claim 12, where the facer sheet is made of a metallicmaterial.
 18. The method of claim 12, where the false joints are formedvia a press operation.
 19. The method of claim 12, wherein the corematerial comprises an insulating foam core material.
 20. A buildingpanel comprising: a facer sheet having opposed side joints; a linersheet; a core material bonded between the facer and liner sheets; and atleast one false joint formed in the facer sheet extending between theside joints such that the facer sheet is a continuous sheet across theat least one false joint, where the at least one false joint comprises:a base surface extending into the foam core; opposing side surfacesconnecting the base surface to the facer sheet; and a tab formed on eachopposing side surface at one of the side joints, the tabs folded underthe one side joint.
 21. The building panel of claim 20, wherein the atleast one false joint is U-shaped in cross-section.
 22. The buildingpanel of claim 20, further comprising a joint closure provided on theside joint at the at least one false joint.
 23. The building panel ofclaim 20, wherein the facer and liner sheets comprise a metallicmaterial, and wherein the core material comprises and insulating foamcore material.